3A+G Technology & Turnkey Production Solution BY XFS COMMUNICATIONS, INC.
1 Influence of Connectors Attenuation on Fiber Network Performance The larger the attenuation, the greater the decrease in power received, thus increasing the bit-error-rate (BER). A receiver discards damaged packets due to bit errors and asks for them to be retransmitted, thus adding to latency. Connectors with extremely low attenuation help to lower BER at the receiver and to reduce latency, thereby boosting network performance. As the data rate continues to increase, the influence of the connectors attenuation on network performance will become more pronounced. Extremely low loss connectors are a future proof solution.
2 3A+G : World s No.1 Fiber Optic Connector A A A-grade Optical Performance Random mated insertion loss (SM) 0.07dB (average) 0.12dB (for 97% of samples) Return loss (APC) 70dB Return loss (UPC) 55dB Extremely low insertion loss + high return loss = No.1 optical performance Zero scratches and defects on ENTIRE ferrule s end-face 3D specs are stricter than IEC s while polishing first-pass rate > 99% Telcordia reliability test passed A-grade 3D Geometry Radius of curvature (mm): 6.5 x 9 (SC/APC) Apex offset (μm): 0 x 30 Fiber height (nm): -30 x 30 APC angle ( ): 7.8 x 8.2 Key error ( ): -0.2 x 0.2 Fiber connectors are widely known as the weakest and most problematic points in a fiber network. XFS proposes 3A+G as the performance and reliability level for our SM/MM patchcords, pigtails and pre-terminated cables with most connector types of SC, LC, FC, ST, MU, E2000, MT and MT-RJ. A-grade End-face Quality 100% of the entire ferrule end-faces of our fiber optic connectors are free of dirt, scratch and chipping GR-326-CORE Certified Passed Telcordia GR-326-CORE testing conducted by Telcordia Network & Product Integrity (NPI) in Piscataway, NJ, USA A G
3 3A+G : World s No.1 Fiber Optic Connector A A-GRADE OPTICAL PERFORMANCE "3A+G" connector has an average random mated insertion loss of just 0.05dB to 0.07dB, exceeding the performance level of IEC 61753-1 Grade B. Its power loss is merely 1.1% to 1.6%, or onetenth of the industry average. "3A+G" 3A+G Connector s Optical Performance (single-fiber connector) manufacturing process is easy to operate and produce, delivers high yields, and uses ordinary materials to produce superb Item Parameter Reference optical performance. It is a revolutionary production technology that produces the Single mode Multimode best quality for low costs. Insertion loss Random mated average 0.07dB; Random mated average 0.05dB; IEC 61300-3-34 Random mated for 97% 0.12dB Random mated for 97% 0.10dB Return loss 70dB (APC); 45dB IEC 61300-3-6 55dB (UPC)
4 3A+G : World s No.1 Fiber Optic Connector A A-GRADE OPTICAL PERFORMANCE SM APC Random Mated Insertion Loss Distribution 350 300 250 IEC 61753-1 Grade B mean IEC 61753-1 Grade B max SM APC Return Loss Distribution 400 350 300 IEC 61753-1 Grade 1 200 150 100 50 250 200 150 100 50 0 0,01 0,02 0,03 0,04 0,05 0,06 0,07 0,08 0,09 0,1 0,11 0,12 0,13 0,14 0,15 0,16 0,17 0,18 0,19 0,2 0,21 0,22 0,23 0,24 0,25 0 60 61 62 63 64 65 66 67 68 69 70,5 71,0 72,0 73,0 74,0 75,0 76,0 77,0 78,0 79,0 80,0 80,5 81,0 81,5 82,0 82,5 MM Random Mated Insertion Loss Distribution 400 350 300 MM Return Loss Distribution 350 300 250 250 200 150 100 200 150 100 50 50 0 0 0,01 0,02 0,03 0,04 0,05 0,06 0,07 0,08 0,09 0,1 0,11 0,12 0,13 0,14 0,15 0,16 0,17 0,18 0,19 0,2 0,21 45,0 45,5 46,0 46,5 47,0 47,5 48,0 48,5 49,0 49,5 50,0 50,5 51,0 51,5 52,0 52,5 53,0 53,5 54,0 54,5 55,0
5 3A+G : World s No.1 Fiber Optic Connector 3A+G fiber optic connector has more rigorous end-face geometry than IEC: the radius of curvature, A A-GRADE 3D GEOMETRY apex offset, fiber height and APC angle have all been effectively controlled for exceptional product consistency and optical performance. More importantly, despite such rigorous specifications, 3A+G manufacturing process can still achieve a polishing first-pass yield of over 99%. Radius of curvature SC/APC 3A+G 6.5mm 9mm IEC 61755-3-2 5mm 12mm LC/APC 3A+G 6mm 12mm IEC 61755-3-2 5mm 12mm SC/UPC 3A+G 10mm 15mm IEC 61755-3-1 5mm 30mm LC/UPC 3A+G 7mm 15mm IEC 61755-3-1 5mm 30mm
6 3A+G : World s No.1 Fiber Optic Connector A A-GRADE 3D GEOMETRY Fiber height SC/APC, LC/APC, SC/UPC, LC/UPC 3A+G -30nm 30nm IEC 61755-3-2-100nm 100nm Apex offset SC/APC, LC/APC, SC/UPC, LC/UPC 3A+G 0μm 30μm IEC 61755-3-2 0μm 70μm APC angle SC/APC, LC/APC 3A+G 7.8 8.2 IEC 61755-3-2 7.5 8.5
7 3A+G : World s No.1 Fiber Optic Connector End-face Examination Standard (SM) Zone A A-GRADE END-FACE QUALITY Range (μm) XFS IEC 61300-3-35 ed2.0 (APC) Scratches Defects Scratches Defects A: Core 0 to 25 None None 4 3μm None B: Cladding 25 to 115 None None No limit No limit < 2μm 5 from 2μm to 5μm None > 5μm For end-face quality, IEC guidelines allow a small number of defects that are small in size. 3A+G fiber optic connector is the first in the industry to deliver connectors with zero defects on the entire ferrule end face. Thus the connector s lightextraction efficiency is optimized, and its top-notch optical performance can hardly be matched by other manufacturers. Zero defects in the Core, Cladding and Adhesive zones C: Adhesive 115 to 135 None None No limit No limit D: Contact 135 to 250 None None No limit None > 10μm E: Rest of ferrule None None No limit No limit The Contact zone and its edges are also free of defects
8 3A+G : World s No.1 Fiber Optic Connector G Flammability Test Intermateability Test GR-326-CORE CERTIFICATION BY TELCORDIA/ERICSSON Optical Performance Test Thermal Age Test Thermal Cycle Test Humidity Aging Test Humidity/Condensation Cycling Test Post-Condensation Thermal Cycle Test Vibration Test Flex Test Twist Test Proof Test Transmission With Applied Tensile Load Test Impact Test Durability Test End of Test Criteria Test Dust Test Adhesive Testing Airborne Contaminants Test Salt Spray Test Immersion/Corrosion Test Groundwater Immersion Test Ferrule Endface Geometry Test Connector Installation Test Extended Thermal Age Test Extended Humidity Test Extended Thermal Cycle Test Telcordia GR-326-CORE is one of the most rigorous reliability testing criteria in the industry. "3A+G APC optical jumpers have passed the GR-326-CORE testings conducted by Telcordia's NPI division in New Jersey, USA. XFS SC/APC 3.0mm Jumper Testing Certificate XFS SC/APC 0.9mm Jumper Testing Certificate
9 3A+G : World s No.1 Fiber Optic Connector M EXTREMELY LOW LOSS MPOS: THE BEST SOLUTION FOR DATACENTER INTERCONNECT MPO connectors are well-suited for high-density, high-traffic applications. XFS manufacturing process employs one of the most advanced polishing technologies for producing MPOs with the best optical performance in the industry. Optical Performance (12c MPO Connector) Item Parameter Reference Endface Geometry (12c MPO Connector) XFS IEC 61755-3-31:2015 Single mode Multimode Minus Coplanarity (nm) 200 400 Ferrule Surface X-Angle ( ) -0.075 to +0.075-0.15 to +0.15 Typ. 0.1dB 0.05dB Ferrule Surface Y-Angle ( ) 7.8 to 8.2 7.8 to 8.2 Insertion loss IEC 61300-3-4 Fiber Height (nm) 1300 to 1800 1000 to 3500 Fiber Differential Height-All (nm) 200 Not defined Max. 0.25dB 0.15dB Fiber Differential Height-Adj. (nm) 150 300 Fiber Tip Spherical Radius (mm) 1 1 Return loss APC: 65dB; UPC: 50dB 35dB IEC 61300-3-6 Ferrule Surface X-Radius (mm) 2000 2000 Ferrule Surface Y-Radius (mm) 50 5 With XFS proprietary polishing technology, we can produce low-loss MPOs without using low-loss MT ferrules. Core Dip (nm; for MM) 0 to 100 Not defined Geometry Limit 10 17.4
10 3A+G : World s No.1 Fiber Optic Connector M EXTREMELY LOW LOSS MPOS: THE BEST SOLUTION FOR DATACENTER INTERCONNECT XFS Standard SM MPO 150 Telcordia GR-1435-CORE Ultra grande (max.) XFS Standard MM MPO 250 Telcordia GR-1435-CORE Ultra grande (max.) Insertion Loss Distribution 120 Insertion Loss Distribution 200 90 150 60 100 30 50 0 0,01 0,03 0,05 0,07 0,09 0,11 0,13 0,15 0,17 0,19 0,21 0,23 0,25 0,27 0,29 0,31 0,33 0,35 0 0,01 0,03 0,05 0,07 0,09 0,11 0,12 0,14 0,16 0,18 0,20 0,22 0,24 0,26 0,28 0,30 0,32 0,34 XFS Standard SM MPO Return Loss Distribution 200 Telcordia GR-1435-CORE Ultra grande (min.) XFS Standard MM MPO Return Loss Distribution 250 150 200 150 100 50 0 65,1 65,6 66,1 66,6 67,1 67,6 68,1 68,6 69,1 69,6 70,1 70,75 71,25 71,75 72,25 72,75 100 50 0 35,1 35,6 36,1 36,6 37,1 37,6 38,1 38,6 39,1 39,6 40,1 40,6 41,1 41,6 42,1 42,6 43,1 43,6 44,1 44,6 45,1 45,5 46 46,5 47 47,5 48 48,5 49 49,5 50
Revolutionary Production Technology for Manufacturing Fiber Optic Connectors
PEOPLE MACHINE MATERIAL SYSTEM The production process is greatly simplified and drastically different from traditional ones. Operator training time is reduced from 30 to 7 days. Jigs are used for all procedures for reducing human error and improving efficiency. Innovative, self-developed equipment: High performance polishing machine for realizing top quality optical termination with low cost. Multi-functional inspection machine for efficient quality checking. Comprehensive material control: Unique material supply chain and production monitoring system for effectively controlling material quality. 3A+G process uses only ordinary materials for producing with the best performance. Process control system: Selfdeveloped. First in the industry. Using barcode management means the state of every work station is known and immediate action can be taken, greatly boosting management efficiency and improving yields. 12 3A+G Production Technology "3A+G" production technology made systematic, scientific and revolutionary changes to the four main factors in manufacturing: people, machine, material and system. It is a complete manufacturing solution with self-developed processes, machines, tools, material management system and quality control system. "3A+G" production technology achieves what has never been achieved in the industry before: consistent mass production of A-Grade fiber optic connectors at a low cost.
13 3A+G Production Technology: Patents Patent name: AN END-TO-END METHOD FOR MANUFACTURING FIBER OPTIC CONNECTORS WITH ZERO INSERTION LOSS AND HIGH RETURN LOSS Type: invention patent Applicant: XFS Communications, Inc. Patent No.: 201610266527.8 This invention discloses a method for manufacturing fiber optic connectors with zero loss. The method includes trimming, pre-assembly, fiber fixing, back-assembly, adhesive removal and polishing treatment. The aforementioned polishing treatment uses independently controlled polishing jigs to perform the polishing procedure in a spiral manner. During the polishing process, the abrasive in progressively reduced in size. The aforementioned fiber optic connector product is affixed to the aforementioned polishing jig and polished on high-precision polishing machines to become the final fiber optic connector product. The manufacturing method of zero-loss fiber optic connectors in this invention possesses the following features: consistent quality, low quality risk, high production efficiency, excellent optical performance, low signal transmission lose, good overall performance and low cost. Patent name: HIGH-PRECISION INTELLIGENT POLISHING MACHINE Type: utility model patent Applicant: XFS Communications, Inc. Patent name: HIGH-EFFICIENT 3D GEOMETRY INTERFEROMETRIC TESTING METHOD & TOOL Type: utility model patent Applicant: XFS Communications, Inc. Patent name: A POLISHING METHOD USED FOR MAKING FIBER OPTIC CONNECTORS WITH ZERO INSERTION LOSS AND HIGH RETURN LOSS Type: invention patent Applicant: XFS Communications, Inc. Patent No.: 201610270137.8 This invention discloses a polishing method used for making lossless fiber optic connectors. The fiber optic connector uses independent controlled polishing jigs to perform a spiral polishing process. The polishing jig includes the jig body. The jig body features connector holding cavities parallel and independent of each other. All connector holding cavities have a connector mount at the base. Attached to the connector mount is a holding column for securing the fiber optic connector in place. At the top of the holding column is a uni-directional screw that is used to move the top of the connector holding cavity. A spring that can move up and down is set into the top of the connector holding column. During the polishing process, the abrasive is progressively reduced in size. The fiber optic connector product is affixed to the polishing jig and polished on the high-precision polishing machine. This polishing method for manufacturing zero-loss fiber optic connectors in this invention possesses the following features: excellent optimal performance, low signal transmission lose, good overall performance and low cost. Patent name: INSERT LOSS AND END-FACE COMBINED INSPECTION MACHINE Type: utility model patent Applicant: XFS Communications, Inc. Patent name: LONGITUDINAL FIBER STRIPPING TOOL Type: utility model patent Applicant: XFS Communications, Inc.
14 3A+G Production Technology: Competitive Advantages A-grade product with optimized optical performance and reliability Self-developed longitudinal heat stripping technology for eliminating fiber damage Self-developed constant temperature curing technology for effectively blocking the impact of environment on adhesive and greatly increasing connector s tensile strength Self-developed intelligent polishing technology with fully digital control and high-precision polishing surface Self-developed simplified 3D inspection technology for reducing testing time by 90% Optimized SOPs for eliminating human error, realizing high yields and efficiency All production process are carried out with jigs for simplifying manual operations and reducing human error Multi-functional equipment are employed to greatly reduce production time Factory zoning is applied to realize a flexible production, improving efficiency for both high-volume, low-mix and low-volume, high-mix production Self-developed Process Control System for real-time monitoring, analyzing and controlling of production process to effectively improve yields and efficiency Optimized low-cost manufacturing, realizing top-notch quality with competitive cost structure A vertically integrated model is employed that most of the components, jigs, tools and equipments are made in-house Multiple polishing procedures of short durations are employed for greatly reducing consumption of polishing films and pads The compatibility issue between fiber and ferrule core is effectively addressed, in that ordinary ferrules and connector kits can be used for producing A-grade products Innovative on-line cleaning procedure (OCP) effectively controls the cleanness of end face, in that a clean room is not needed for achieving 100% A-grade output Turnkey production module optimized for fast deployment of manufacturing line and MP 3A+G production technology is integrated into a modularized, end-to-end turnkey plant export solution including production line planning and establishment; design and manufacturing of jigs, tools and equipment; installation/testing/operation/maintenance of jigs, tools and equipment; personnel training; raw material and consumable selection; pilot to mass production and quality assurance; follow-up technical support
15 3A+G Production Technology: APC Polishing Proprietary polishing process reinvents traditional polishing machine for intelligent, high-precision, One-Button Operation surface polishing. The technology is based on independent polishing. The pressure is applied to each connector by an individual spring. The polishing path of each connector is separate with overlap so grime and powder does not cross over. The technology progressively reduces abrasive size over six polishing procedures: D30, D15, D9, D3, D1 and ADS. Each of the six polishing procedures last for not over 30 seconds. Multiple short polishing procedures allow timely removal of produced powder, improving polishing quality and extending polishing films re-use times. POLISHING FILM USAGE PROCEDURE 3A+G D30 20 secs D15 20 secs D9 30 secs POLISHING PATH ON A POLISHING FILM 3A+G D3 30 secs Fully utilize the top, down, left, right side of polishing film D1 30 secs ADS 30 secs
16 World's First Patchcord Factory Turnkey Production Solution our office
17 Modularized Turnkey Production Solution With over 30 years of experience of manufacturing fiber patchcords for the most prestigious customers in the industry, XFS now proudly introduces the world s first patchcord factory turkey production solution for helping worldwide manufacturers establish the capability of producing the world-class quality patchcords with low capital expenditure and competitive product cost structure. The turnkey solution includes: the end-to-end production line planning and establishment; design and manufacturing of equipment, fixtures and tools; installation/testing/ operation/maintenance of equipment, fixtures and tools; personnel training; material and consumable selection; pilot production and quality assurance; and continued technical support. The turnkey solution is based on one module producing 3500 ends of SC/APC (or 4500 ends of LC/APC) connections with 100% 3A+G level over one 10-hour shift. FACTORY ESTABLISHMENT Optimize factory layout, equipment placement and personnel allocation based on profit target OPERATOR TRAINING Unique operator training system for minimizing human error while production MATERIAL SUPPLY Comprehensive material supply support system collaborating seamlessly with 3A+G manufacturing process EQUIPMENT SUPPORT Turnkey plant export of equipment and tools; training on equipment operation; long-term maintenance service PRODUCTION SUPPORT Experienced technical team is stationed on-site for solving production problems and ramping up yield and efficiency CONTINUED UPGRADE XFS has continued to refine its manufacturing process over years. Improvements are exported to customers on a regular basis
18 Modularized Turnkey Production Solution XFS MODULE The standardized 3A+G production process for manufacturing fiber interconnect products including pigtails, patchcords, pre-terminated cables and MPO assemblies are combined into a module built around the 3A+G polishing process Each module has 6 polishing machines and needs a total of 10 operators The turnkey solution is based on one module producing 3500 ends of SC/APC (or 4500 ends of LC/APC) connections with 100% 3A+G level over one 10-hour shift. Self-developed equipment and tools with simplified SOPs are employed for minimizing investment cost, maximizing production efficiency and achieving the best quality CABLE CUTTING High-precision, high-efficiency automated equipment Fuzzy color identification of length for efficiency and convenience Standard operating process GLUE REMOVAL Quick and effective removal of cured glue on front end of the core Easy to use, more effective and much cheaper than conventional laser cleaver for glue removal GLUE ROOM Store glue at constant temperature and humidity to ensure consistent quality Thorough mixing of AB glue by precisely controlled ratio CONNECTOR KITS ASSEMBLY Fixed longitudinal stripping for consistent length Stripping jig for high efficiency Easy-to-use visual alignment method FERRULE S EXTRUSION LENGTH MEASUREMENT CCD visual inspection Set up different polishing groups based on ferrule s length to ensure consistent polishing pressure and height FIXTURE CENTER Constant cleaning and maintenance of polishing fixtures to ensure high level of consistency in polishing quality Polishing fixtures dimensions and spring pressure are under constant monitoring FIBER CURING Fiber stripping machine can be set for fixed time and temperature for high efficiency without fiber damage Small oven insulated from ambient temperature for stable curing POLISHING Multiple short polishing procedures improve polishing and increase first-pass rate Next-generation high-precision polishing machine for even more stable polishing Simple 3D geometry and end face inspectors to significantly improve QA efficiency BACK-END ASSEMBLY Inner and external assembly frames for efficiency, convenience and error proofing Long moment arm with high pressure riveting press for steady pressure and good results PACKAGING Sort into cartons and package in order for high efficiency http://v.youku.com/v_show/id_xmtyxodg0odyxmg==.html
Product performance (IL, RL, 3D, end face quality) is the best in the world Product reliability has GR-326-CORE certification by Telcordia/Ericsson High yield; 3D geometry polishing first-pass rate > 99% 3A+G production process is a revolutionary technology that can consistently produce high-quality products at low cost. Our turnkey solution can give patchcord manufacturers a quantum leap in technological advancement in a short amount of time! Production process is simple, stable and efficient, thus less operators are needed and skilled workers are not needed, greatly reducing labor costs Ordinary ferrules, connector kits and consumables are sufficient for producing A-grade products, greatly reducing material costs All equipment and tools are self-developed, greatly reducing the investment in fixed assets
TAIWAN OFFICE: 5F-1, No.2, Ln.57, Chongyang Rd., Taipei 11573, Taiwan CHINA FACTORY: Bldg.B, No.9 Jiejiabao Rd., Shiyan, Baoan District, Shenzhen 518108, China sales@xfsconnect.com +86-755-2675-5668 xfsconnect.com For the past 30 years, we focus only on making the best optical termination in the world. Charles Sun, CEO, XFS